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The development of entire car bodies benefits from simulations, especially if they are performed at an early stage of development. Simulations lower the costs for required car body modifications. This paper focuses on dip painting simulation and describes the simulation process by detecting badly painted areas and liquid carry overs. A new hydrodynamic method has been benchmarked to CFD and real-life results. Results will be shown together with case examples. The solver is similar to, and as accurate as, standard CFD solvers; it is faster in its computation speed by a factor of at least 1000. The electrophoretic deposition (ELPO) of an entire car body can be simulated overnight with ALSIM. How is this possible? This paper points out the reason for all of this.

Simulations need high quality mesh representations as input which are often manually prepared. The fully automatic mesh preprocessor software MERGE avoids this time consuming task. The software CAD or STL data as input, repairs invalid meshes and merges the input objects together. Small gaps between the input objects are automatically closed. The output surface mesh can be supplied in two different flavors, either as a mesh that minimizes the number of elements or as a mesh consisting of high quality triangles, ready for 3D meshing. A closed and connected surface mesh of an entire car body can be prepared overnight in a fully automatic manner.